Apparatus and method for sequentially packing an interval of a wellbore

Abstract

An apparatus ( 38 ) and method for sequentially packing an interval of a wellbore ( 32 ) is disclosed. The apparatus ( 38 ) comprises a cross-over assembly ( 40 ) having first and second exit ports ( 58, 62 ). The cross-over assembly ( 40 ) has a fracturing configuration wherein the first exit port ( 58 ) is open and the second exit port ( 62 ) is closed and a gravel packing configuration wherein the first exit port ( 58 ) is closed and the second exit port ( 62 ) is open. The apparatus ( 38 ) also includes a gravel packing assembly ( 42 ) that has an inlet that receives the gravel packing slurry from the second exit port ( 62 ) and a plurality of outlets ( 72 ) that allow for the delivery the gravel slurry to a plurality of locations along the length of a sand control screen ( 52 ).

What is claimed is:  
     
       1. A method for sequentially packing an interval of a wellbore comprising the steps of: 
       traversing a formation with the wellbore;  
       locating a sand control screen within the wellbore proximate the formation;  
       disposing a sequential packing apparatus proximate the sand control screen, the sequential packing apparatus having a first exit port and a second exit port;  
       positioning the sequential packing in a first position wherein the first exit port is open and the second exit port is closed;  
       pumping a first fluid into the sequential packing apparatus such that the first fluid exits the sequential packing apparatus through the first port;  
       operating the sequential packing apparatus from the first position to the second position wherein the first exit port is closed and the second exit port is open; and  
       pumping a second fluid into the sequential packing apparatus such that the second fluid exits the sequential packing apparatus through the second port.  
     
     
       2. The method as recited in  claim 1  wherein the step of pumping a first fluid into the sequential packing apparatus such that the first fluid exits the sequential packing apparatus through the first port further comprises the step of pumping the first fluid into the sequential packing apparatus such that the first fluid exits the sequential packing apparatus through the first port at a pressure above the formation fracture pressure. 
     
     
       3. The method as recited in  claim 1  wherein the step of pumping a first fluid into the sequential packing apparatus such that the first fluid exits the sequential packing apparatus through the first port further comprises the step of pumping a fluid slurry containing propping agents into the sequential packing apparatus. 
     
     
       4. The method as recited in  claim 1  further comprising, after the step of pumping a first fluid into the sequential packing apparatus such that the first fluid exits the sequential packing apparatus through the first port, the step of fracturing the formation. 
     
     
       5. The method as recited in  claim 1  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising shifting a first section of the sequential packing apparatus relative to a second section of the sequential packing apparatus. 
     
     
       6. The method as recited in  claim 1  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising operating a first valve from an open position to a closed position to prevent fluid flow through the first exit port and operating a second valve from a closed position to an open position to allow fluid flow through the second exit port. 
     
     
       7. The method as recited in  claim 1  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising shifting a sleeve within the sequential packing apparatus. 
     
     
       8. The method as recited in  claim 1  wherein the step of pumping a second fluid into the sequential packing apparatus such that the second fluid exits the sequential packing apparatus through the second port further comprises the step of pumping a fluid slurry containing gravel into the sequential packing apparatus and out through the second port. 
     
     
       9. The method as recited in  claim 8  further comprising the step of terminating pumping the fluid slurry containing gravel when an annulus between the sand control screen and the wellbore is substantially completely packed with the gravel. 
     
     
       10. The method as recited in  claim 1  wherein the step of pumping a second fluid into the sequential packing apparatus such that the second fluid exits the sequential packing apparatus through the second port further comprises the step of discharging the second fluid into a gravel packing assembly comprising a plurality of conduits extending substantially the length of the sand control screen, each conduit having a plurality of discharge ports in a sidewall section thereof. 
     
     
       11. The method as recited in  claim 1  wherein the step of pumping a second fluid into the sequential packing apparatus such that the second fluid exits the sequential packing apparatus through the second port further comprises the step of discharging the second fluid into a gravel packing assembly substantially positioned around the sand control screen to form a first annulus between the gravel packing assembly and the wellbore, the gravel packing assembly comprising an outer tubular and an inner tubular disposed within the outer tubular forming a second annulus therebetween, the second annulus including an axially extending slurry passageway and an axially extending production pathway, the slurry passageway being in fluid isolation from the production pathway. 
     
     
       12. The method as recited in  claim 11  wherein the step of discharging the second fluid into a gravel packing assembly further comprises discharging the second fluid into the slurry passageway such that the second fluid exits the slurry passageway through an outlet in the outer tubular, the inner tubular having no openings adjacent the slurry passageway, both the outer and inner tubulars adjacent the production pathway having a plurality of openings. 
     
     
       13. The method as recited in  claim 11  further comprising the step of disposing an isolation member within the second annulus to define the slurry passageway and the production pathway and to prevent fluid communication therebetween. 
     
     
       14. The method as recited in  claim 13  wherein the step of disposing an isolation member within the second annulus further comprises disposing an isolation member within the second annulus having a pair of substantially parallel, circumferentially spaced apart, axially extending members that radially extend between the outer and inner tubulars and a pair of substantially parallel, axially spaced apart, circumferentially extending members that radially extend between the outer and inner tubulars defining the slurry passageway and the production pathway and preventing fluid communication therebetween. 
     
     
       15. The method as recited in  claim 1  wherein the first fluid and the second have the same composition. 
     
     
       16. A method for sequentially fracturing and gravel packing an interval of a wellbore comprising the steps of: 
       traversing a formation with the wellbore;  
       locating a sand control screen within the wellbore proximate the formation;  
       disposing a sequential packing apparatus proximate the sand control screen, the sequential packing apparatus having first and second exit ports;  
       positioning the sequential packing in a first position wherein the first exit port is open and the second exit port is closed;  
       pumping a fluid slurry containing propping agents into the sequential packing apparatus such that the fluid slurry containing propping agents exits through the first port at a pressure above the fracture pressure of the formation;  
       operating the sequential packing apparatus from the first position to the second position wherein the first exit port is closed and the second exit port is open;  
       pumping a fluid slurry containing gravel into the sequential packing apparatus such that the fluid slurry containing gravel exits through the second port; and  
       discharging the fluid slurry containing gravel into a gravel packing assembly.  
     
     
       17. The method as recited in  claim 16  further comprising, after the step of pumping a fluid slurry containing propping agents into the sequential packing apparatus such that the fluid slurry containing propping agents exits through the first port at a pressure above the fracture pressure of the formation, the step of fracturing the formation. 
     
     
       18. The method as recited in  claim 16  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising shifting a first section of the sequential packing apparatus relative to a second section of the sequential packing apparatus. 
     
     
       19. The method as recited in  claim 16  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising shifting a sleeve within the sequential packing apparatus. 
     
     
       20. The method as recited in  claim 16  wherein the step of operating the sequential packing apparatus from the first position to the second position further comprising operating a first valve from an open position to a closed position to prevent fluid flow through the first exit port and operating a second valve from a closed position to an open position to allow fluid flow through the second exit port. 
     
     
       21. The method as recited in  claim 16  further comprising the step of terminating pumping the fluid slurry containing gravel when an annulus between the sand control screen and the wellbore is substantially completely packed with the gravel. 
     
     
       22. The method as recited in  claim 16  wherein the step of discharging the fluid slurry containing gravel into a gravel packing assembly further comprises the step of discharging the fluid slurry containing gravel into a plurality of conduits extending substantially the length of the sand control screen, each conduit having a plurality of discharge ports in a sidewall section thereof. 
     
     
       23. The method as recited in  claim 16  wherein the step of discharging the fluid slurry containing gravel into a gravel packing assembly further comprises the step of discharging the fluid slurry containing gravel into a gravel packing assembly substantially positioned around the sand control screen to form a first annulus between the gravel packing assembly and the wellbore, the gravel packing assembly comprising an outer tubular and an inner tubular disposed within the outer tubular forming a second annulus therebetween, the second annulus including an axially extending slurry passageway and an axially extending production pathway, the slurry passageway being in fluid isolation from the production pathway. 
     
     
       24. The method as recited in  claim 23  wherein the step of discharging the second fluid into a gravel packing assembly further comprises discharging the second fluid into the slurry passageway such that the fluid slurry containing gravel exits the slurry passageway through an outlet in the outer tubular, the inner tubular having no openings adjacent the slurry passageway, both the outer and inner tubulars adjacent the production pathway having a plurality of openings. 
     
     
       25. The method as recited in  claim 23  further comprising the step of disposing an isolation member within the second annulus to define the slurry passageway and the production pathway and to prevent fluid communication therebetween. 
     
     
       26. The method as recited in  claim 25  wherein the step of disposing an isolation member within the second annulus further comprises disposing an isolation member within the second annulus having a pair of substantially parallel, circumferentially spaced apart, axially extending members that radially extend between the outer and inner tubulars and a pair of substantially parallel, axially spaced apart, circumferentially extending members that radially extend between the outer and inner tubulars defining the slurry passageway and the production pathway and preventing fluid communication therebetween. 
     
     
       27. The method as recited in  claim 16  wherein the fluid slurry containing propping agents and the fluid slurry containing gravel have the same composition. 
     
     
       28. An apparatus for sequentially packing an interval of a wellbore comprising: 
       a sand control screen;  
       a cross-over assembly having first and second exit ports, the cross-over assembly having a first position wherein the first exit port is open and the second exit port is closed and a second position wherein the first exit port is closed and the second exit port is open; and  
       a gravel packing assembly having an inlet that is in fluid communication with the second exit port, the gravel packing assembly having a plurality of outlets that are located proximate the sand control screen and that extend along the gravel packing assembly substantially the length of the sand control screen.  
     
     
       29. The apparatus as recited in  claim 28  wherein the cross-over assembly further comprises a sleeve having first and second positions, in the first position of the sleeve, the first exit port of the cross-over assembly is open and the second exit port of the cross-over assembly is closed, in the second position of the sleeve, the first exit port of the cross-over assembly is closed and the second exit port of the cross-over assembly is open. 
     
     
       30. The apparatus as recited in  claim 28  wherein the cross-over assembly further comprises first and second valves, the first valve being in an open position and the second valve being in a closed position when the cross-over assembly is in the first position, the first valve being in a closed position and the second valve being in an open position when the cross-over assembly is in the second position. 
     
     
       31. The apparatus as recited in  claim 28  wherein the gravel packing assembly further comprises a plurality of conduits extending substantially the length of the sand control screen, each conduit including at least one of the outlets in a sidewall section thereof. 
     
     
       32. The apparatus as recited in  claim 28  wherein the gravel packing assembly further comprises an outer tubular and an inner tubular disposed within the outer tubular forming an annulus therebetween, the annulus including an axially extending slurry passageway and an axially extending production pathway, the slurry passageway being in fluid isolation from the production pathway. 
     
     
       33. The apparatus as recited in  claim 32  wherein the portion of the outer tubular adjacent to the slurry passageway includes the outlets, wherein the portion of the inner tubular adjacent the slurry passageway has no openings and wherein both the outer and inner tubulars adjacent the production pathway having a plurality of openings. 
     
     
       34. The apparatus as recited in  claim 32  further comprising an isolation member disposed within the annulus defining the slurry passageway and the production pathway and preventing fluid communication therebetween. 
     
     
       35. The apparatus as recited in  claim 34  wherein the isolation member further comprises a pair of substantially parallel, circumferentially spaced apart, axially extending members that radially extend between the outer and inner tubulars and a pair of substantially parallel, axially spaced apart, circumferentially extending members that radially extend between the outer and inner tubulars defining the slurry passageway and the production pathway and preventing fluid communication therebetween. 
     
     
       36. The apparatus as recited in  claim 28  further comprising a wash pipe disposed within the sand control screen to take returns, the wash pipe in fluid communication with a return port of the cross-over assembly when the cross-over assembly is in the second position. 
     
     
       37. An apparatus for sequentially packing an interval of a wellbore having a sand control screen disposed therein, the apparatus comprising: 
       a packer having a sealing surface positioned within the wellbore;  
       a cross-over assembly partially disposed within the packer, the cross-over assembly having first and second exit ports positioned on one side of the packer and a return port positioned on the other side of the packer, the cross-over assembly having a first position wherein the first exit port is open, the second exit port is closed and the return port is closed and a second position wherein the first exit port is closed, the second exit port is open and the return port is open;  
       a gravel packing assembly having an inlet that is in fluid communication with the second exit port of the cross-over assembly, the gravel packing assembly having a plurality of outlets that are located proximate the sand control screen and that extend along the gravel packing assembly substantially the length of the sand control screen; and  
       a wash pipe disposed within the sand control screen to take returns, the wash pipe in fluid communication with the return port when the cross-over assembly is in the second position.  
     
     
       38. The apparatus as recited in  claim 37  wherein the cross-over assembly further comprises a sleeve having first and second positions, in the first position of the sleeve, the first exit port is open while the second exit port and the return port are closed, in the second position of the sleeve, the first exit port is closed while the second exit port and the return port are open. 
     
     
       39. The apparatus as recited in  claim 37  wherein the cross-over assembly further comprises first, second and third valves, the first valve is in an open position while the second and third valves are in a closed position when the cross-over assembly is in the first position, the first valve is in a closed position while the second and third valves are in an open position when the cross-over assembly is in the second position. 
     
     
       40. The apparatus as recited in  claim 37  wherein the gravel packing assembly further comprises a plurality of conduits extending substantially the length of the sand control screen, each conduit including at least one of the outlets in a sidewall section thereof. 
     
     
       41. The apparatus as recited in  claim 37  wherein the gravel packing assembly further comprises an outer tubular and an inner tubular disposed within the outer tubular forming an annulus therebetween, the annulus including an axially extending slurry passageway and an axially extending production pathway, the slurry passageway being in fluid isolation from the production pathway. 
     
     
       42. The apparatus as recited in  claim 41  wherein the portion of the outer tubular adjacent to the slurry passageway includes the outlets, wherein the portion of the inner tubular adjacent the slurry passageway has no openings and wherein both the outer and inner tubulars adjacent the production pathway having a plurality of openings. 
     
     
       43. The apparatus as recited in  claim 41  further comprising an isolation member disposed within the annulus defining the slurry passageway and the production pathway and preventing fluid communication therebetween. 
     
     
       44. The apparatus as recited in  claim 43  wherein the isolation member further comprises a pair of substantially parallel, circumferentially spaced apart, axially extending members that radially extend between the outer and inner tubulars and a pair of substantially parallel, axially spaced apart, circumferentially extending members that radially extend between the outer and inner tubulars defining the slurry passageway and the production pathway and preventing fluid communication therebetween.